Systems for producing biodiesel and processes for using the same

ABSTRACT

The present invention relates to systems for producing biodiesel, including a batch-continuous flow system, and to processes using the system.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of U.S. Provisional Applications Ser. Nos. 60/787,466, filed Mar. 30, 2006 and 60/862,072, filed Oct. 19, 2006, each of which are incorporated by reference in its entirety.

FIELD OF INVENTION

The present invention relates to a system for producing biodiesel and to processes using the system.

BACKGROUND OF THE INVENTION

Diesel is a fuel source that is made from fossil fuel oil (usually, petroleum), which is used in a particular type of internal combustion engine—namely, a compression ignition engine called a diesel engine. Conversely, biofuel is a renewable energy source derived from recently living organism or their byproducts (i.e., biomass). A type of biofuel is biodiesel, which is a clean burning fuel alternative that is a diesel-equivalent usually made from vegetable oils or animal fats. Biodiesel, therefore, is a particularly promising fuel alternative.

Neat biodiesel (i.e., 100% biodiesel) has been designated as an alternative fuel by the U.S. Department of Energy (DOE) and the U.S. Department of Transportation (DOT). See e.g., National Biodiesel Board, FAQs (frequently asked questions), available at http://www.nbb.org/resources/faqs/default.shtm (last accessed, Mar. 28, 2006). Today, biodiesel is the only alternative fuel to have fully completed the health effects testing requirements of the U.S. 1990 Clean Air Act Amendments. Id. Using biodiesel in a conventional diesel engine results in a considerable reduction of unburned hydrocarbons, carbon monoxide, and particulate matter emissions compared to those from using of diesel fuel. Id. Also, the emissions of sulfur oxide and sulfates (major components of acid rain) from using biodiesel are essentially eliminated compared to those from using diesel fuel. Id.

Also, biodiesel that meets industry and government quality standards is very non-toxic. The National Biodiesel Board reports that biodiesel has an acute oral LD₅₀ (lethal dose at 50%) of about greater than 17.4 g/kg, which by comparison makes biodiesel ten times less toxic than table salt. (National Biodiesel Board, Environmental & Safety Information, available at www.biodiesel.org/pdf_files/Envi&Safetyinfo.PDF (last accessed, Mar. 28, 2006). The biodiesel, rapeseed ethyl esters (REE), was found to have an LD₅₀ of about greater than 5 g/kg, when administered by gastric intubation. (Varsho, B. J. Acute Oral Toxicity Study of 100% REE in Albino Rats, Ashland, Ohio: WIL Research Laboratories, Inc. (1996) (Study No. WIL-275003), available at www.biodiesel.org/resources/reportsdatabase/reports/gen/19960110_gen-220.pdf (last accessed, Mar. 28, 2006). Additionally, the benign nature of biodiesel has been readily reported by the fact that it degrades as fast as sugar. (See e.g., National Biodiesel Board, Environmental & Safety Information; U.S. Environmental Protection Agency, “U.S. EPA Gives $69,000 to University of Nevada to Find Ways to Improve Alternative Fuel,” [Press Release] (Aug. 5, 2004), available at www.epa.gov/cgi-bin/epaprintonly.cgi (last accessed, Mar. 28, 2006).

Further benefits of biodiesel have been confirmed by, for example, a 1998 biodiesel life-cycle study, jointly sponsored by the U.S. DOE and the U.S. Department of Agriculture, which concluded biodiesel reduces net carbon dioxide emissions by 78% compared to petroleum diesel (see, e.g., Sheehan, J. et al. Life Cycle Inventory of Biodiesel and Petroleum Diesel for Use in an Urban Bus. Golden, Colo.: National Renewable Energy Laboratory (May 1998), p. 7 (NREL/SR-580-24089) and by scientific research demonstrating that biodiesel exhaust has a less harmful impact on human health than petroleum diesel fuel (see e.g., Linhjem, C. and A. Pollack, Impact of Biodiesel Fuels on Air Quality and Human Health: Task 1 Report. Golden, Colo.: National Renewable Energy Laboratory (May 2003) (NREL/SR-540-33794).

Also, when reviewing the high cost associated with other alternative fuel systems, many fleet managers, i.e., individuals responsible for the efficient operation of an organization's vehicles (fleets), have determined that biodiesel is their least-cost strategy to comply with state and federal regulations associated with alternative fuels. The cost-benefits of biodiesel further are improved for fleet managers because use of biodiesel does not require any modifications to conventional engines; thus, fleet managers can retain their fleets, inventories of spare parts, refueling stations and skilled mechanics without incurring additional costs. Biodiesel and biodiesel blends, therefore, are good candidates for replacing fossil fuels as primary transportation energy sources.

However, the production of biodiesel often uses large, expensive production facilities that operate as continuous flow systems. Each continuous flow system has multiple, custom built vessels for each step in the production process (e.g, reaction, polishing, and drying steps), each of which can cost about $100,000. The vessels of such continuous flow operations require computerization, such as computerized values, level controls and automated flow detection. Often the detectors, software and systems are dedicated and have little value if the process or facility changes; or they have little value even for contemplation of a change in the process or facility (i.e., lack adaptability). Also, because the system is continuous flow, when there is an issue, for example, at the end of the process, the entire system needs to be slowed down in unison, or one area will overload in respect to the biodiesel reaction mixture, causing a breakdown in the production of the biodiesel.

Because these continuous flow systems often are extremely expensive and large batch systems, they generally are inefficient in actual production of a biodiesel. For example, such systems prevent large quantities of materials from successfully producing a biodiesel because the agitator of the system can not effectively contact a substantial amount of the material, while large quantities of reaction mixture often have problems maintaining the correct reaction temperature throughout the mixture during the reaction step. These systems also often require refined organic oils and animal fats. Producers using these systems generally use refined oils and fats (i.e., feedstock), which cost more than crude oils and fats, or pre-treat crude feedstocks before production, therefore, incurring an often costly upfront expenditure. At the end of the process, these producers generally have an additional expense in the form of further processing the waste product of the system (e.g., crude glycerin (i.e., about 75% to 85% glycerin) in order to have a usable product (such as a food grade glycerin that can be used in, e.g., pharmaceuticals, consumer products and livestock feeds).

Therefore, there is a need for a more flexible, less expensive, more efficient and effective system for producing a biodiesel fuel. It now has been found that such a system is possible. The system of the present invention uses less costly equipment than a continuous flow system, and this equipment also is more adaptable than the customized equipment of the popular continuous flow systems. The present invention is directed to such a system and processes for using the same.

SUMMARY OF THE INVENTION

The present invention provides a system for producing a biodiesel, the system having (a) optionally, at least one reagent storage vessel; (b) optionally, at least one reagent mixing vessel; and (c) at least one batch reactor, where the batch reactor contains (i) at least one agitator; (ii) at least one baffle, where optionally, the baffle is heated; (iii) at least one pump; and (iv) at least one mixer. In some embodiments, the system further comprises a post-reactor network, where the post-reactor network contains (i) optionally, at least one separator holding vessel, (ii) optionally, at least one separator; (iii) at least one polishing vessel; (iv) optionally, at least one co-product storage vessel; (v) optionally, at least one drying vessel; and (vi) optionally, at least one biodiesel storage vessel.

The present invention also provides a system for producing a biodiesel, the system having (a) optionally, at least one reagent storage vessel; (b) optionally, at least one reagent mixing vessel; (c) at least one batch reactor, where the batch reactor contains (i) at least one agitator; (ii) at least one baffle, where optionally, the baffle is heated; (iii) at least one pump; and (iv) at least one mixer; and (d) a post-reactor network, where the post-reactor network contains (i) optionally, at least one separator holding vessel, (ii) optionally, at least one separator; (iii) at least one polishing vessel; (iv) at least one co-product storage vessel; (v) optionally, at least one drying vessel; and (vi) at least one biodiesel storage vessel.

In some such embodiments, the baffles of the batch reactor are heated. In some such embodiments, the system further makes a co-product. In some such embodiments, the system is a batch system. In some such embodiments, the system is a batch-continuous flow system.

The present invention further provides a process for producing a biodiesel, the process involving the steps of:

-   -   1. selecting a feedstock;     -   2. optionally, mixing at least a first reagent and a second         reagent, thereby, creating a reagent mixture;     -   3. feeding the feedstock into a batch reactor;     -   4. optionally, delivering a first reagent to the feedstock in         the batch reactor, thereby creating a first reaction mixture;     -   5. optionally, delivering a second reagent to the feedstock in         the batch reactor, thereby creating a second reaction mixture;     -   6. optionally, delivering the reagent mixture of step 2 to the         feedstock in the batch reactor, thereby creating a reaction         mixture;     -   7. heating the reaction mixture of steps 4 and 5 or step 6,         thereby providing a heated reaction mixture;     -   8. mixing the heated reaction mixture by:         -   a. agitating the reaction mixture using an agitator;         -   b. rotating the reaction mixture using at least one baffle;             and         -   c. re-circulating the reaction mixture using a pump and a             mixer,     -   for a predetermined time and under predetermined conditions to         produce a biodiesel-containing composition;     -   9. separating the biodiesel of the biodiesel-containing         composition from the non-biodiesel composition, thereby         obtaining a crude biodiesel product;     -   10. optionally, transferring the non-biodiesel composition to a         co-product storage tank, thereby retaining a co-product;     -   11. polishing the crude biodiesel product, thereby obtaining a         polished biodiesel product;     -   12. optionally, drying the polished biodiesel product, thereby         obtaining a biodiesel product; and     -   13. storing the biodiesel product of either step 11 or step 12;     -   where if step 2 is performed, then step 6 is performed and steps         4 and 5 are not performed; and if step 2 is not performed, then         step 6 is not performed and steps 4 and 5 are performed.

In some embodiments, the process of the present invention uses the system of the present invention.

BRIEF SUMMARY OF DRAWINGS OF THE INVENTION

FIG. 1: An ariel view of a batch reactor and of a baffle of the present invention.

FIG. 2: An ariel view and side view of the piping and heating of baffles of the present invention.

FIG. 3: A transparent view of a batch reactor of the present invention.

FIG. 4: A side view and a top view of a baffle of the present invention positioned inside a batch reactor of the present invention.

FIG. 5: An expanded view of a baffle of the present invention.

FIG. 6: An aerial view of a propeller unit of an agitator of the present invention positioned inside a batch reactor of the present invention.

FIG. 7: A schematic representation of a demethanolation unit of a biodiesel production system of the present invention.

FIG. 8. A schematic representation of the drying step of a process of the present invention that can be used in a biodiesel production system of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Definitions. In describing the present invention, the following terms will be used and are intended to be defined as indicated immediately below. Definitions for other terms can occur throughout the specification. It is intended that all terms used in the specification include the plural, active tense and past tense forms of a term.

As used herein, the term “baffle” refers to a means used for obstructing the flow of a liquid, solid, or gas.

As used herein, the phrase “batch-continuous flow system” refers to a system having a substantially large batch reactor (e.g., about 12,500 gallons capacity) that feeds a continuous flow post-reactor network. In the batch reactor, a feedstock is reacted with reagents under conditions and for a time so as to produce a reaction mixture containing a biodiesel and a co-product. The post-reactor network is where the reaction mixture is processed, thereby providing individually a biodiesel product and a co-product, both of which are in usable form.

As used herein, the phrase “batch reactor” refers to a particular type of “reactor” (defined below) used to gather, produce, or process substances that are treated as a single unit (“batches”), as opposed to a continuous process, which often is used in “batch production” (i.e., a method of processing or producing a product in units), as opposed to in “continuous production” (i.e., a method of processing or producing a product without interruption).

As used herein, the term “biodiesel” refers to a renewable energy source made from plants and animals, and their byproducts. Biodiesel includes, for example and without limitation, mono-alkyl esters of long-chain fatty acids made from oils and animal fats, oxygenates of such esters, and alkane (non-oxygenate) biodiesel, i.e., biomass-to-liquid (BTL) fuel, where a whole plant is converted enzymatically or by gasification. Biodiesel includes renewable fuel for diesel engines derived from organic oils (e.g., soybean oil) and which meets industry and governmental regulations, such as ASTM D 6751 in the U.S. Neat biodiesel (i.e., 100% biodiesel) is designated as B100. Biodiesel meeting the ASTM D 6751 standard is a fuel and a fuel additive.

As used herein, the term “biodiesel blend” refers to a mixture of biodiesel meeting ASTM D 6751 specifications and petroleum-based diesel fuel, which is designated as BXX, where XX represents the volume percentage of biodiesel fuel in the the blend.

As used herein, the term “bleached” refers to the removal of e.g., coloring materials, and natural and synthetic contaminants.

As used herein, the term “co-product” refers to the non-biodiesel composition produced by the present invention.

As used herein, the term “degummed” refers to the removal of waxes, phosphates and other impurities.

As used herein, the term “eddy” refers to the phenomenon where a swirling fluid and a reverse current is created when the fluid flows past an obstacle. The phenomenon occurs when a flowing fluid creates a space devoid of downstream-flowing fluid on the downstream side of the obstacle, and fluid behind the obstacle flows into the void creating a swirl of fluid on each edge of the obstacle, followed by a short reverse flow of fluid behind the obstacle flowing upstream, toward the back of the obstacle.

As used herein, the phrase “feed stock” refers to a substance that is introduced into the system, generally, at the point of the reactor, from which the biodiesel is produced. Feedstocks useful with the present invention include, for example, and without limitation, (a) organic oils, such as corn, cottonseed, mustard seed, olive, palm, peanut, rapeseed including canola, soybean, and sunflower; (b) waste vegetable oil (WVO), which is vegetable oil that is no longer usable in food preparations; (c) animal fats, such as, (i) tallow (e.g., beef and sheep fat), (ii) lard (e.g., swine fat), (iii) yellow grease, which is restaurant waste grease that contains animal products (e.g., beef tallow), (iv) brown grease, which is any grease from sources who free fatty acid content exceeds limits for animal feeds or greases that are restricted from use in animal feeds, such as trap grease, black grease and sewage grease, and (v) fish oils, such as omega-3 fatty acids; (d) plants of the genus, Jatropha, such as Jatropha curcas; (e) hemp; (f) mustard; (g) soybeans and (h) algae. Oils used for producing biodiesel can be, e.g., unrefined or crude (i.e., not processed), first refined (e.g., degummed) and refined (i.e., processed, such as to be free of impurities, e.g., bleached).

As used herein, the phrase “post-reactor network” refers to an interconnected or interrelated group of steps or devices, which may or may not be individually performing or operating, that occur after events associated with a reactor.

As used herein, the term “reactants” refers to an original substance entering into a chemical reaction. In the present invention, a feedstock and a reagent are both reactants.

As used here, the term “reaction” refers to a chemical process in which one substance is transformed into another substance or substances.

As used herein, the term “reactor” refers to a device for containing or controlling a reaction (e.g., a chemical reaction), such as a reaction necessary for producing biodiesel, e.g., transesterification of soybean oil.

As used herein, the term “reagent” refers to a substance used in a chemical reaction so as to detect, measure, or produce other substances.

As used herein, the term “refined” means processed, treated, or where physical and chemical contaminants have been removed, and includes, “re-refined,” i.e., a recycled substance or removal of physical and chemical contaminants acquired through use of a substance.

As used herein, the term “transesterification” refers to a reversible acid- or base-catalyzed chemical reaction where an alcohol compound displaces the alcohol moiety (i.e., alkoxy group) of an ester compound. Transesterification is the alcoholysis of an ester, i.e., a chemical reaction where a solvent that is an alcohol cleaves one or more bonds in a reacting solute, such as an ester compound of the feedstock of the present invention.

As used herein, the term “unrefined” or crude” means unprocessed, untreated, raw, virgin or in a natural state.

In one aspect, the present invention relates to a system for producing biodiesel. In some embodiments, the system of the present invention includes a batch reactor. In some embodiments, the system of the present invention includes a batch reactor and a post-reactor network. In some embodiments, the batch reactor of the system of the present invention contains an agitator, a baffle, a pump and a mixer. The agitator is a means used for stirring and blending the feedstock and reagents (i.e., the reactants). In some embodiments, the agitator includes a plurality of blades. The blades of the agitator are from about 5% to about 50% of the diameter of the reactor. In some embodiments, the plurality of blades is mounted on a shaft, thereby forming a propeller unit of the agitator. In some embodiments, the agitator is located in the center of the batch reactor. In some embodiments, the propeller unit (22) is mounted off-centered to the shaft (21) (see, e.g., FIG. 6). In some embodiments, the propeller is mounted centered to the shaft. In some embodiments, the agitator enters the batch reactor from the top; in some embodiments, from the bottom. The agitator has a motor, which drives the propeller unit. In some embodiments, the motor of the agitator has a power from about 20 horsepower (hp) to about 120 hp. In some embodiments, the power of the motor of the agitator is about 25 hp. In some embodiments, the agitator further includes a pump, such as a mild (low carbon) steel or stainless steel pump (e.g., a 600 gallons per minute (gpm) pump comprising a low carbon or stainless steel).

The baffle of the reactor of the present invention effectively mixes a reaction mixture that an agitator blends, which often is not sufficiently mixed for good production of a biodiesel. The blending by an agitator often results in a reaction mixture (e.g., feedstock, reagents, and any biodiesel, co-product and intermediates thereof) spinning around a reactor and increasing the reaction time necessary to produce a biodiesel and a co-product. The baffle of the reactor of the present invention further moves a reaction mixture, which provides greater interaction of the materials of a reaction mixture and thus, decreases the reaction time necessary to produce a biodiesel and a co-product. In some embodiments, the batch reactor has a plurality of baffles. In some embodiments, the batch reactor has at least one baffle. In some embodiments, the batch reactor has from about 2 baffles to about 5 baffles; from about 4 baffles to about 7 baffles; or from about 6 baffles to about 10 baffles. In some embodiments, as shown in FIG. 4, the baffle (2) of the batch reactor of the present invention (1) is affixed to the inside wall (3) of the reactor where the baffle has a cavity (4) that allows the baffle to be substantially offset from the side of the reactor, which allows the reaction mixture to pass between the wall of the batch reactor and the baffle and thereby ensuring that reaction mixture in the reactor is substantially mixed. In some embodiments, a baffle of the present invention is affixed 90 degrees to the inside wall of the batch reactor. In some embodiments, the baffles are located between the wall of the batch reactor and the agitator (e.g., between the internal wall of the reactor and the shaft of the propeller unit of the agitator). In some embodiments, the baffles surround the agitator. To reduce the likelihood of a baffle creating an eddy during the mixing of the reaction mixture, in some embodiments, a baffle of the present invention has a design that provides for a cavity in which the reaction mixture can pass, e.g., a slot, a curvature, a notch and a slit. As shown in FIG. 5, in some embodiments, a baffle (2) of the present invention includes two arms (13) perpendicular to a main body (11) of the baffle, which thereby forms a cavity (4) behind the main body of the baffle and has a second cavity (12) in the main body, both cavities allowing the reaction mixture to pass, reducing the occurrence of eddies. In some embodiments, a baffle of the batch reactor is hollowed or rounded inward (e.g., concave), thereby allowing the reaction mixture to pass in the cavity created by the concave nature of the baffle, and thus, reducing the occurrence of eddies. In some embodiments, the occurrence of eddies is substantially reduced. In some embodiments, the occurrence of eddies is essentially eliminated.

The occurrence of eddies during the mixing of the reactants in the batch reactor can be further reduced or eliminated by the use of a heated baffle in the batch reactor of the present invention. In some embodiments, a heated baffle is directly heated from a heat source. In some embodiments, the heat source is steam. In some embodiments, the steam is low pressure steam. As used herein, “low pressure steam” refers to steam of which the pressure is less than, equal to, or not greatly above, that of the atmosphere. In some embodiments, the baffle of the present invention comprises piping, which is directly connected to the heat source. For example, and without limitation, low pressure steam is pumped through the piping of the baffle, thereby heating the piping as the steam travels through it. The temperature of the heated baffle can be from about 50° F. to about 200° F. In some embodiments, the temperature of the heated baffle is from about 170° F.; about 180° F.; about 190° F. or about 200° F. The use of a heated baffle also keeps the reaction mixture in the reactor at a stable temperature; thus, aiding the efficiency of the reaction time. In some embodiments, the piping (5) of a baffle (2) of the present invention lies vertical to the reactor (see FIG. 4).

In some embodiments, a baffle (1) of the present invention includes piping (8) directly connected to a heat source (30), such as, e.g., a hot water heater. (See, e.g., FIG. 2). The hot water is pumped through the piping of the baffle, thereby heating the piping as hot water travels through it. In some such embodiments, the temperature of the heated baffle can be from about 50° F. to about 200° F. In some such embodiments, the temperature of the heated baffle is from about 170° F.; about 180° F.; about 190° F. or about 200° F. The use of a heated baffle also keeps the reaction mixture at a stable temperature; thus, aiding the efficiency of the reaction time.

The baffles of the batch reactor can be constructed from chemical and heat resistant (though, preferably, heat convective or thermally conductive) materials. For example, and without limitation, a baffle can include a steel, such as, carbon steel, stainless steel, and a chromium plated steel, a copper, an aluminum, a metal alloy, a thermally conductive polymer (e.g., any of the CoolPoly® thermally conductive plastics from Cool Polymers, Inc., Warwick, R.I.), a polyvinyl chloride, an expoxy, a fluoroplastic, a polypropylene, a polyimide, a polyacetal, a polycarbonate, an acrylonitrile-butadiene-styrene, a polyetheretherketone, a polybutylene, a polyphenylene oxide, a polyphenylene sulfide, a liquid crystal polymer, or any combination thereof. In some embodiments, a baffle of the batch reactor is constructed from pipe, where the pipe contains at least one compound selected from a carbon steel, stainless steel, a chromium plated steel, a copper, an aluminum, a metal alloy, a thermally conductive polymer, a polyvinyl chloride, an expoxy, a fluoroplastic, a polypropylene, a polyimide, a polyacetal, a polycarbonate, an acrylonitrile-butadiene-styrene, a polyetheretherketone, a polybutylene, a polyphenylene oxide, a polyphenylene sulfide or a liquid crystal polymer. In some embodiments, the piping of the baffle comprises steel. In some such embodiments, the baffle is affixed to the reactor by welding. The baffle can be of various sizes. For example, and without limitation, the baffle can have a length from about 1 foot to about 20 feet (inclusive of endpoints) and a width of about 3 inches to about 70 inches (inclusive of endpoints).

The batch reactor of the present invention also includes a pump and a mixer, which provide for the effective mixing and agitation of the reaction mixture in the reactor. Where the agitator of the batch reactor of the present invention keeps the reaction mixture blended, the pump and the mixer of the reactor ensure that the reaction mixture remains mixed as it re-circulates through the batch reactor via the mixer and the pump during a reaction period (i.e., the period of time in which a reaction is deemed completed). For example, an agitator of the present invention can have a plurality of blades on a propeller unit that rotate at about 145 revolutions per minute (rpm) to about 185 rpm, whereby the propeller unit causes the reaction mixture to rotate in the direction of the propeller unit while it pushes the reaction mixture downward, thus, blending the reaction mixture from the top to the bottom of the reactor. Simultaneously, the flow of the rotating reaction mixture is interrupted by a baffle of the present invention, and if the baffle is heated, the reaction rate of the reaction mixture passing the baffle increases. Further, the mixing of the reaction mixture is effectively turbulent to efficiently produce a biodiesel and a co-product because the pump and the mixer of the batch reactor force the reaction mixture from the bottom of the reactor at a high flow rate (e.g., about 600 gpm), causing an entire reactor volume of reaction mixture (e.g., about 12,000 gallons) to be circulated through the mixer at a substantially fast rate (e.g., about every twenty (20) minutes). When a portion of the reaction mixture is re-circulated through the pump and the mixer, the portion is sent to the top of the batch reactor where it is shot to the other side of the reactor, further mixing as it crashes down onto the upper surface of the reaction mixture.

As the reaction continues, the reactants and any biodiesel and co-product produced can separate. For example, if the feedstock is soybean oil and the reagents are an alcohol, such as methanol, and a catalyst, such as sodium hydroxide (often referred to as lye or caustic soda), transesterification of the soybean oil occurs, producing soy methyl esters as a biodiesel and a co-product comprising glycerin and fatty acids. The heavier glycerin molecules try to fall to the bottom of the reactor, while the lighter soy methyl ester molecules remain at the top of the reactor. Although the agitator provides some mixing of the reaction mixture, it is the pump and the mixer of the present invention that ensures the reaction mixture does not separate; and thus, the pump and the mixer provide for an efficient reaction time because of the ability to reintroduce a portion of the reaction mixture into the remaining portion of the reaction mixture under the pressure of the pump through the mixer.

The pump (6) and the mixer (7) of the batch reactor of the present invention are connected externally to the batch reactor 1), while inside the reactor is an agitator (20) having a shaft (21) with a propeller (22). (See, FIG. 3). The pump (6) and the mixer (7) are placed in-line of piping (8) that runs vertically (i.e., from top to bottom) along the outside of the batch reactor (1), and where the piping (8) is connected to the reactor (1) at points near the top (9) and the bottom (10) of the reactor (1). When piping is used as the means to connect the pump and the mixer to the batch reactor, the piping can contain any of the materials described previously for piping that comprise a baffle of the present invention. In some embodiments, the pump of the batch reactor is a high speed pump. In some embodiments, the pump of the batch reactor has a flow rate from about 20 gpm to about 1,200 gpm. In some embodiments, the pump has a flow rate of about 100 gpm to about 1,000 gpm; from about 200 gpm to about 800 gpm; from about 400 gpm to about 600 gpm. In some embodiments, the pump has a flow rate of about 600 gpm. In some embodiments, the pump has a motor of about 20 hp to about 120 hp. In some embodiments, the pump has a motor of about 75 hp, such as a 3500 rpm U.S. Electric Motors™ motor (Emerson Electric Co., St. Louis, Mo.) Other suitable pumps are readily known to one skilled in the art such as those manufactured by Baldor Electric Co. (Fort Smith, Ariz.), General Electric Co. (Stamford, Conn.), and Dayton Electric Manufacturing Co. (Niles, Ill.; a subsidiary of Grainger W. W., Inc. (Lake Forest, Ill.)), including brands such as Dayton™ motors. The power of the motor of the pump should be scaled to the flow rate of the pump and the viscosity of the feedstock, for example, a 20 hp motor on a pump with a 200 gpm flow rate for use with highly viscous feedstocks, a 75 hp motor on a 600 gpm pump for moderately viscous feedstocks, and a 250 hp motor on a 1200 gpm pump for least viscous feedstocks. As used herein, the term “viscosity” or “viscous” refers the property of a fluid to resist to sheer forces and thus, flow. Also, one skilled in the art will know how to modify the pump elements, such as motor, flow rate, the inlet and the outlet thereof, to accommodate various viscosities of feedstocks.

In some embodiments, the pump of the batch reactor is a centrifugal pump. As used herein, the phrase “centrifugal pump” refers to a device that transfers or circulates fluids by the use of a force that impels the fluid outward from a center of rotation (i.e., centrifugal force). A useful pump for the batch reactor of the present invention includes, without limitation, the Gould MTX 3600 series, 600 gpm pump (Gould Pumps, ITT Industries, Seneca Falls, N.Y.). Other suitable pumps for the reactor of the present invention will be readily known to those skilled in the art.

In some embodiments, the mixer of the batch reactor of the present invention is a static mixer. As used herein, the phrase “static mixer” or “motionless mixer” refers to a device that is fixed in a pipe so as to mix a liquid that is passed through it. In some embodiments, the static mixer of the batch reactor has from 1 to about 24 elements. As used herein, the term “element” refers the number of deflection plates mounted inside the mixer. In some embodiments, the mixer of the reactor of the present invention has from about 2 to about 18 elements; from about 3 to about 12 elements; or from about 3 to about 6 elements. In some embodiments, the mixer of the reactor of the present invention has about 3; about 4; about 5; or about 6 elements. In some embodiments, the mixer of the reactor has about 3 elements; in some embodiments, the mixer has about 4 elements. A useful static mixer for the present invention includes, without limitation, a Ross LPD static mixer (Ross Mixing, Inc., Port St. Lucie, Fla.). In some embodiments, the mixer of the reactor of the present invention is a Ross LPD static mixer having about 4 elements. Other suitable mixers for the present invention are those well known to one skilled in the art, for example, static/motionless mixers manufactured by Ross Mixing Inc. and Koflo Corporation (Cary, Ill.).

In some embodiments, the batch reactor of the system of the present invention includes an agitator that is a motor and blade, a plurality of heated baffles, a centrifugal pump and a static mixer.

In addition to the batch reactor described above, the system of the present invention can include a post-reactor network. The post-reactor network of the present system provides for the processing of the reaction mixture of the batch reactor so that a usable biodiesel and co-product are achieved. The post-reactor network includes a group of components where each component satisfies a different need in achieving a usable biodiesel and co-product. In some embodiments, each component of the post-reactor network can operate individually, i.e., separate and distinct from the other components of the post-reactor network. In such an embodiment, the system of the present invention is a batch system, i.e., each component used in production of a biodiesel and a co-product—from batch reactor to storage vessel—is used in its own, single, distinct operation, and thus, not in connection with another component used in production. In some embodiments, each component of the post-reactor network operates simultaneously with the other components of the post-reactor network. In such an embodiment, each component of the post-reactor network used in the production of a biodiesel and a co-product is performed in unison and continuously with the other post-reactor components. Therefore, in some embodiments, the system of the present invention is a batch-continuous flow system, i.e., a component in the production of a biodiesel and a co-product is performed either in a batch or a continuous flow environment—e.g., the reaction step of the system is performed in a batch reactor (i.e., a batch) while the processing of the resulting reaction mixture of the batch reactor is performed in a post-reactor network whose components operate continuously and without interruption from each other.

In some embodiments, the post-reactor network of the present system includes optionally, at least one separator holding vessel, optionally, at least one separator, at least one polishing vessel, at least one co-product vessel, optionally at least one drying vessel; and at least one biodiesel storage vessel. The optional separator holding vessel receives the reaction mixture from the batch reactor and feeds it to the optional separator. On the other hand, the optional separator holding vessel can hold the reaction mixture following receipt of the mixture and gravity separation is allowed to occur, thus producing at least a crude biodiesel and a co-product. If the optional separator of the post-reactor network receives the reaction mixture, the separator divides the reaction mixture into at least a crude biodiesel and a co-product. For example, and without limitation, if the reaction mixture resulted from the reaction of a soybean oil feedstock, methanol and sodium hydroxide, the reaction mixture would contain soy methyl esters (a biodiesel), glycerin and fatty acids (a co-product), and miscellaneous materials, such as intermediates and minor products of the reactants, and unreacted oil, methanol and sodium hydroxide. With such a reaction mixture, gravity or the separator of the present post-reaction network would divide apart the soy methyl esters (a lighter phase) from the glycerin and fatty acids (a heavier phase) with each phase containing any respectively dense miscellaneous materials. In some embodiments, the optional separator is a liquid phase separator. In some embodiments, the optional separator is a centrifuge, such as an Alfa Laval MAP 207 and Alfa Laval MOPX 209 (Alfa Laval, Inc. Houston, Tex.). Other suitable separators for use in the system of the present invention are known readily to one skilled in the art and include those manufactured by Westfalia Separator A.G. (Oelde, Germany), Ishikawajima-Harima Heavy Industries Co., Ltd. (IHI) (Tokyo, Japan), and Triton Systems LLC (Dearborn, Mich.).

Often once a crude biodiesel and a co-product have been separated from each other, the crude biodiesel is transferred to a polishing vessel, while the co-product is transferred to a co-product vessel. When a crude biodiesel is in a polishing vessel, it is polished, i.e., the crude biodiesel is washed and cleaned of residual reagents, such as alcohol and catalyst, and of residual glycerin, fatty acids and/or miscellaneous materials. In some embodiments, the polishing vessel of the post-reactor network of the present system includes a means from which a liquid polishing agent, such as water, is delivered into the polishing vessel. For convenience, such a means will be referred to herein as a “wash head” and this phrase is not meant to limit the means for delivering a liquid polishing agent, including, its design nor location. As used herein, the phrase “polishing agent” refers to any substance that removes unwanted impurities from a mixture. A polishing agent can be a liquid, a solid or a gas. In some embodiments, the polishing vessel includes a plurality of wash heads. In some embodiments, the polishing vessel includes from about 1 to about 5 wash head, from about 3 to about 7 wash heads; from about 5 to about 10 wash heads; or from about 10 to about 20 wash heads. In some embodiments, the polishing vessel includes about 5 wash heads. In some embodiments, a wash head of the polishing vessel delivers about 1 gpm of liquid polishing agent to about 100 gpm of liquid polishing agent. The amount of liquid polishing agent delivered by a wash head of the polishing vessel will depend on vessel size and number of wash heads of the polishing vessel. For example, and without limitation, a polishing vessel having about a diameter of about 8 feet (ft.) and a height of about 20 ft. could have 1 to about 5 wash heads, each of which delivers about 50 gpm of liquid polishing agent; or the polishing vessel could have a 20 ft. diameter and be 20 ft. high and thus, have about 10 to about 20 wash heads, each of which delivers 100 gpm of liquid polishing agent. A wash head of the polishing vessel of the present invention is located higher than the height of a liquid to be polished (e.g., a crude biodiesel), and located so as to provide for even delivery of the liquid polishing agent over the surface of the liquid in the polishing vessel. In some embodiments, a wash head of the polishing vessel is located in the roof of the polishing vessel. In some embodiments, a wash head of the polishing vessel is located inside the polishing vessel at a point higher than the maximum height of a liquid to be polished in the vessel. In some such embodiments, a wash head is located on an internal wall of the polish vessel. In some such embodiments, a wash head is located on a pole in the polishing vessel; in some such embodiments, a wash head is located on a rod in the vessel. In some such embodiments, the pole or rod is located in the center of the vessel. In some embodiments, the polishing vessel has a means for delivering a solid polishing agent, such as a magnesium silicate (e.g., Magnesol®, The Dallas Group of America. Whitehouse, N.J.). In some embodiments, the polishing vessel has a means for controlling the flow rate of a crude biodiesel into it. In some embodiments, the polishing vessel contains a solid polishing agent prior to introduction of a crude biodiesel into the vessel.

Optionally, the post-reactor network of the system of the present invention includes a drying vessel. Often a drying vessel is included when the polishing of a crude biodiesel uses a liquid polishing agent. In some embodiments, the drying vessel includes a heating element, a vacuum and a means for delivering the liquid polished biodiesel into it. For example, and without limitation, the liquid polished biodiesel is delivered into a drying vessel, which is heated and under vacuum pressure, i.e., under pressure below atmospheric pressure. For example, the liquid washed biodiesel is sprayed against a heated, internal wall of the drying vessel, where it slides down the heated, internal wall of the drying vessel into a holding pot at the bottom of the drying vessel. Any residual reagent, such as alcohol, and water in the polished biodiesel are steamed (i.e., vaporized) and drawn away because of the heat (e.g., about 150-300° F.) and vacuum pressure. The resulting dried and polished biodiesel (i.e., a biodiesel product), which is now refined and ready for use, is transferred to a biodiesel storage vessel, such as a tank. Any residual reagent, such as methanol, and liquid polishing agent, such as trace amounts of water when water is the liquid polishing agent, that vaporized during the drying process are condensed via condensers (i.e., apparatus that converts a substance from a vapor state to a liquid state), and the resulting condensed reagent and/or polishing agent (e.g., methanol and/or water, respectively) are collected and transferred to a reagent storage vessel, such as an alcohol storage vessel.

In some embodiments, the system of the present invention optionally includes components prior to the batch reactor. In some such embodiments, the system further includes a reagent storage vessel, for example, an alcohol storage vessel. In some embodiments, the system includes a reagent mixing vessel. In a reagent mixing vessel, the reagents to be added to the feedstock in the batch reactor are pre-mixed. For example, in a reagent mixing vessel, a reagent, such as an alcohol like methanol, is mixed with another reagent, such as a catalyst, e.g., sodium hydroxide, and this resulting mixture is then added to the batch reactor containing a feedstock, such as soybean oil.

In some embodiments, the system for producing a biodiesel of the present invention includes (a) optionally, at least one reagent storage vessel; (b) optionally, at least one reagent mixing vessel; (c) at least one batch reactor, where the batch reactor contains (i) at least one agitator; (ii) at least one baffle, where optionally, the baffle is heated; (iii) at least one pump; and (iv) at least one mixer; and (d) a post-reactor network, where the post-reactor network contains (i) optionally, at least one separator holding vessel, (ii) at least one separator; (iii) at least one co-product storage vessel, (v) optionally, at least one drying vessel; and (vi) at least one biodiesel storage vessel. In some such embodiments, the baffles of the batch reactor are heated. In some such embodiments, the system further produces a co-product. In some such embodiments, the system is a batch system. In some such embodiments, the system is a batch-continuous flow system. In some embodiments, a vessel that is a component of the system of the invention is used for more than one purpose during actual production of a biodiesel. For example, and without limitation, the separating of a reaction mixture is performed in the batch reactor, and thus, the optional separator holding vessel is not present; or the polishing of a crude biodiesel product is performed in a biodiesel storage tank.

In some embodiments, the system for producing a biodiesel of the present invention includes (a) optionally, at least one reagent storage vessel; (b) optionally, at least one reagent mixing vessel; (c) at least one batch reactor, where the batch reactor contains (i) at least one agitator; (ii) at least one baffle, where optionally, the baffle is heated; (iii) at least one pump; and (iv) at least one mixer; and (d) a post-reactor network, where the post-reactor network contains (i) optionally, at least one separator holding vessel, (ii) at least one separator; (iii) at least one polishing vessel; (iv) at least one co-product storage vessel; (v) optionally, at least one drying vessel; and (vi) at least one biodiesel storage vessel. In some such embodiments, the baffles of the batch reactor are heated. In some such embodiments, the system further produces a co-product. In some such embodiments, the system is a batch system. In some such embodiments, the system is a batch-continuous flow system.

In another aspect, the present invention relates to a process for producing a biodiesel. In some embodiments, the process for producing a biodiesel of the present invention further produces a co-product. In some embodiments, the process of the present invention is a batch system, i.e., each step of the process is performed separate and distinct from another without continuous interaction between each step. In some embodiments, the process is a batch-continuous flow system, i.e., that some steps of the process are performed separate and distinct without continuous interaction with other steps of the process (i.e., in a batch), while other steps in the process continuously interact with other non-batch steps (i.e., in a continuous flow). In some embodiments, the process of the present invention for producing a biodiesel involves using the system of the present invention, as previously described herein.

In some embodiments, the process of the present invention for producing a biodiesel involves the steps of:

-   -   1. selecting a feedstock;     -   2. optionally, mixing at least a first reagent and a second         reagent, thereby, creating a reagent mixture;     -   3. feeding the feedstock into a batch reactor;     -   4. optionally, delivering a first reagent to the feedstock in         the batch reactor, thereby creating a first reaction mixture;     -   5. optionally, delivering a second reagent to the feedstock in         the batch reactor, thereby creating a second reaction mixture;     -   6. optionally, delivering the reagent mixture of step 2 to the         feedstock in the batch reactor, thereby creating a reaction         mixture;     -   7. heating the reaction mixture of steps 4 and 5 or step 6,         thereby providing a heated reaction mixture;     -   8. mixing the heated reaction mixture by:         -   a. agitating the reaction mixture using an agitator;         -   b. rotating the reaction mixture using at least one baffle;             and         -   c. re-circulating the reaction mixture using a pump and a             mixer,     -   for a predetermined time and under predetermined conditions to         produce a biodiesel-containing composition;     -   9. separating the biodiesel in the biodiesel-containing         composition from a non-biodiesel composition, thereby obtaining         a crude biodiesel product;     -   10. optionally, transferring the non-biodiesel composition to a         co-product storage tank, thereby retaining a co-product;     -   11. polishing the crude biodiesel product, thereby obtaining a         polished biodiesel product;     -   12. optionally, drying the polished biodiesel product, thereby         obtaining a biodiesel product, and     -   13. storing the biodiesel product of either step 10 or step 11;     -   where if step 2 is performed, then step 6 is performed and steps         4 and 5 are not performed; and if step 2 is not performed, then         step 6 is not performed and steps 4 and 5 are performed. In some         embodiments, the process of the present invention includes a         baffle that is heated.

In some embodiments, the process of the present invention involves selecting at least one feedstock from a group of feedstocks consisting of organic oils, waste vegetable oil (WVO), animal fats, plants of the genus Jatropha, hemp, mustard, soybeans and algae. In some embodiments, the feedstock is selected from an organic oil. In some such embodiments, the organic oil comprises a corn oil, a cottonseed oil, a mustard seed oil, an olive oil, a palm oil, a peanut oil, a rapeseed oil, a canola oil, a soybean oil, or a sunflower oil. In some embodiments, the feedstock is selected from an animal fat. In some such embodiments, the animal fat comprises beef tallow, sheep tallow, lard, yellow grease, brown grease, trap grease, black grease, sewage grease, fish oil or omega-3 fatty acids. The quality of the oils and fats useful in the present invention can be crude and refined, including degummed and bleached. In some embodiments, the feedstock is selected from plants of the genus Jatropha, Jatropha curcas, hemp, mustard, soybeans and algae. When a feedstock is of a plant source, the feedstock can include the entire plant or parts of the plant, including its leaves, stem, branches, flowers, roots, seeds, or product, such as a fruit or vegetable. In some embodiments, a feedstock includes two or more feedstocks. For example, and without limitation, a feedstock includes a canola oil and a soybean oil. In some such embodiments, the feedstock is a mixture of two or more feedstocks. For example, and without limitation, the feedstock is a mixture of canola oil and soybean oil, which is then fed into a reactor. In some embodiments, the feedstock includes two or more feedstocks, as described previously, where each feedstock is individually fed into a reactor. In some such embodiments, the two or more feedstocks are individually fed into a reactor simultaneously. In some such embodiments, the two or more feedstocks are individually fed into a reactor non-simultaneously.

Useful reagents for the process of the present invention include, without limitation, alcohols and catalysts. Alcohols useful in the process of producing biodiesel include, e.g., C₁-C₈ alkyl alcohols. The term “alkyl,” as used herein, denotes a straight (unbranched) or branched univalent aliphatic group of 1 to 8 carbon atoms including, e.g., methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl and the branched (non-straight-chained) isomers thereof, such as isopropyl. In some embodiments, the alcohol of the process of the present invention is selected from a methanol, an ethanol, a propanol, a butanol, a pentanol, a hexanol, a heptanol, and an octanol. In some embodiments, the alcohol of the process of the present invention is selected from a methanol, an ethanol, a propanol and a butanol. In some embodiments, the alcohol of the process of the present invention comprises a methanol. In some embodiments, the alcohol comprises an ethanol. In some embodiments, the alcohol comprises a propanol, such as isopropanol.

In addition to an alcohol, another reagent useful in the process of the present invention is a catalyst. The term “catalyst,” as used herein refers to a specific type of reagent that is a substance that initiates or increases the rate of a reaction and lowers the activation energy required for the reaction without being consumed itself. Catalysts useful in the process of the present invention include, without limitation, potassium hydroxide, sodium hydroxide, sodium methoxide and sodium ethoxide. In some embodiments, the catalyst of the process of the present invention is selected from sodium hydroxide, potassium hydroxide, sodium methoxide, sodium ethoxide, or a combination thereof. In some embodiments, the catalyst is sodium hydroxide. In some embodiments, the catalyst is sodium methoxide.

The amount of reagents used in the process of the present invention will depend on the amount and type of feedstock used in the process. The amount of reagents used in the process of the present invention can very as a percentage of the amount of feedstock used in the process. In some embodiments, the amount of feedstock used in the process of the present invention is from about 1,000 gallons to about 12,000 gallons. In some embodiments, the amount of feedstock is from about 5,000 gallons to about 11,000 gallons. In some embodiments, the amount of feedstock is from about 6,500 gallons to about 10,000 gallons. In some embodiments, the amount of feedstock is about 6,500 gallons to about 7,000 gallons, or any amount there between in increments of 50 gallons. In some embodiments, the amount of feedstock is from about 8,500 gallons to about 9,000 gallons, or any amount there between in increments of 50 gallons. In some embodiments, the amount of feedstock is an amount in pounds that can be adequately be processed in the reactor of the system being used. In some such embodiments, the amount of feedstock is from about 1,000 to about 100,000 lbs.

In some embodiments, the amount of alcohol used in the process of the present invention is from about 10% to about 40%, expressed on a volume per volume percent (% v/v) compositional basis. In some embodiments, the amount of catalyst used in the process of the present invention is from about about 250 pounds (lbs.) to about 600 lbs. In some embodiments, the amount of catalyst used in the process of the present invention is from about 5% to about 10%, expressed on a weight per weight percent (% w/w/) compositional basis. In some embodiments, the amount of catalyst in the process of the present invention is about 8% w/w.

In the process of the present invention, the reaction mixture comprising the feedstock and reagents is heated. In some embodiments, the heating of the reaction mixture (i.e., the reaction temperature) during the process of the present invention is at a temperature from about 60° F. to about 200° F.

The mixing of the the process for producing a biodiesel of the present invention is continued for the duration of the reaction of the process, which is the time necessary for the feedstock and reagents to produce a substantial amount of a biodiesel (i.e., the reaction time). Often the reaction time is inversely proportional to the heating temperature of the reaction mixture, though the reaction time also can be dependent on the amount of reaction mixture (i.e., total compositional amount of feedstock and reagents). In some embodiments, the reaction time of the process of the present invention for producing a biodiesel is from about 30 minutes to about 600 minutes. In addition to the temperature at which the reaction is performed and the amount of reactants, the reaction time of the process of the present invention also can depend on the size of batch reactor and the pressure inside the reactor. For example, the pressure inside the reactor, can be influenced by the height above sea level at which the reactor is located, which then can affect the temperature at which the reaction is performed (e.g., methanol boils at different temperatures based on altitude and pressure).

Examples 3-5, hereinbelow, present representative processing parameters (i.e., amounts of feedstock and reagents, and reaction times and temperatures) at which the process of the present invention can be performed.

In some embodiments, the process for producing a biodiesel of the present invention, includes testing the moisture content of the feedstock. In some embodiments, testing the moisture content of the feedstock is performed before the feedstock is fed into a reactor. In some embodiments, the process of the present invention includes drying the feedstock, so as to reduce the moisture content to about less than 3%; to about less than 2%; or to about less than 1%. Because water in the feedstock can inhibit the reaction for producing a biodiesel, removal of water from the feedstock improves the reaction time. In some embodiments, the drying of the feedstock is performed before the feedstock in fed into a reactor. If the feedstock contains from about 1% to about less than 3% moisture, the reaction time can be longer than if the feedstock contains less than about 1% moisture. In some such embodiments, the reaction time is about 10 minutes longer to about 100 minutes longer; or any amount of time in increments of 5 minutes therebetween.

In some embodiments, the process for producing a biodiesel of the present invention involves polishing a crude biodiesel. In some embodiments, the polishing involves a polishing agent selected from a liquid polishing agent or a solid polishing agent. In some embodiments, the polishing agent of the process of the present invention is a liquid polishing agent. In some embodiments, the liquid polishing agent is water. In some embodiments, the liquid polishing agent is aqueous. As used herein, the term “aqueous” means water-based, of, relating to, containing or resembling water. In some embodiments, the liquid polishing agent contains at least one acid. In some such embodiments, the acid is selected from sulfuric acid, phophoric acid or mutaric acid. An acidified liquid polishing agent can be useful in neutralizing a biodiesel product that has a basic pH. For example, a biodiesel of methyl esters can have a basic pH (e.g., pH of about 11) because of the basic catalyst used in the reaction (e.g., sodium hydroxide), and an acid liquid polishing agent can bring the pH of the biodiesel to a more neutral pH (e.g., a pH of about 7). In some embodiments, the liquid polishing agent is sprayed over the top surface of a crude biodiesel product. In some embodiments, the liquid polishing agent is allowed to fall to the bottom of the polishing vessel, and then air is used to create bubbles in the liquid polishing agent; the liquid polishing agent bubbles then travel up through the crude biodiesel product, breaking at the surface, which allows the liquid polishing agent to falls back through the crude biodiesel product. This type of polishing is often referred to as “bubble wash.” The total biodiesel yield from bubble washing often is reduced compared to other types of polishing, likely because of bubble washing creates an emulsion of a crude biodiesel product and liquid polishing agent. As used herein, the term “emulsion” refers to a colloid system in which both the dispersed phase and the dispersion medium are immiscible liquids with the dispersed liquid being the discontinuous phase and the dispersion medium the continuous phase, whereby the dispersed liquid is distributed in small globules throughout the body of the dispersion medium liquid. Common types of emulsions are oil-in-water where oil is the dispersed liquid and an aqueous solution such as water is the dispersion medium and water-in-oil, where conversely, an aqueous solution is the dispersed phase. In some embodiments, the liquid polishing agent is introduced from the top of the polishing vessel while the crude biodiesel product is introduced from the bottom of the polishing vessel, wherein the crude biodiesel product is polished when the falling liquid polishing agent meets the rising crude biodiesel product. This type of polishing is often referred to as “counter current cleaning.” Mixing (e.g., agitating) the liquid polishing agent and crude biodiesel product to promote polishing can be used, however, it can cause a foaming and sudsy quality to the resulting mixture of the crude biodiesel and the liquid polishing agent, because of the presence of residual soaps (i.e., salts of fatty acids derived from a animal fat or an organic oil) in the crude biodiesel product being polished.

A solid polishing agent also can be used in the polishing step of the process of the present invention. In some embodiments, the polishing agent is selected from a magnesium silicate (e.g., Magnesol®), an ion-exchange resin or an absorbent. Examples of ion-exchange resins and absorbents useful as a solid polishing agent are those under the tradenames Amberlite® (e.g., Amberlite® BD 10 Dry) and Amberlyst®, produced by Rohm and Haas Company (Philadelphia, Pa.). In some embodiments, the solid polishing agent is introduced into a crude biodiesel. In some embodiments, a crude biodiesel is introduced to the solid polishing agent. In some such embodiments, the crude biodiesel is poured over the solid polishing agent. In some such embodiments, the solid polishing agent is placed first into a polishing vessel, then a crude biodiesel is poured over the solid polishing agent. In some embodiments, the polishing vessel is about 1 to about 3 times the cubic volume compared to the amount of solid polishing agent placed in the polishing vessel. In some such embodiments, the crude biodiesel is introduced to the solid polishing agent at an opening at the top of the polishing vessel containing the polishing agent. In some embodiments, the crude biodiesel gravimetrically travels through the polishing vessel, thereby interacting with the solid polishing agent. In some embodiments, the crude biodiesel travels under pressure through the polishing vessel, thereby interacting with the solid polishing agent. In some embodiments, the polished biodiesel is collected at the bottom of the polishing vessel and transferred to a biodiesel storage vessel.

In some embodiments, the process for producing a biodiesel of the present invention involves drying a polished biodiesel product. In some embodiments, the drying of the polished biodiesel product involves heating the polished biodiesel under vacuum pressure. See e.g., FIG. 7. In some embodiments, the polished biodiesel (33) is sprayed against a heated, internal wall (31) of the drying vessel (30) (which is under vacuum), where the polished biodiesel slides down the heated, internal wall (31) of the drying vessel (30) into a holding area (e.g., a holding pot) at the bottom of the drying vessel (32). In some embodiments, the dried biodiesel (i.e., a biodiesel product), which is now refined and ready for use, is transferred to a biodiesel storage vessel, such as a tank. In some embodiments, as shown in FIG. 5, the drying of a polished biodiesel (33) further includes condensing any vaporized residual reagent and polishing agent (34) and transferring the resulting condensed reagent and/or polishing agent to a reagent storage vessel (35).

Another embodiment of the drying step of the process of the present invention is illustrated in FIG. 8. The drying step is performed by use of a distillation system as shown in FIG. 8, wherein the reagents, such as alcohol, of the process, are removed from the biodiesel product. The distillation system comprises, for example, and without limitation, evaporator pumps (P1, P2, P3), a hot oil recirculation pump (P4), a pre-filter (F1), condensors (H4, H6, H9), biodiesel pre-heaters (H1-H3, H5, H7, H8) evaporators, such as thin-film evaporators (V1-V3) (i.e., drying vessel), hot oil vent pot (V4), evaporator sprays (SP1-SP3), and an hot oil heater (H01). In such embodiments, polished biodiesel is fed into the pre-filter (F1), which is in fluid communication with the biodiesel pre-heaters (H1-H3, H.5, H7, H8). The heater biodiesel then is pumped to the evaporator sprays (SP1-SP3) and sprayed into the evaporators (V1-V3). The dried biodiesel is passed through the condensors are fed from the evaporators (V1-V3) via the evaporator feed pumps (P1-P3) as finished product to a storage vessel (not shown). The vaporized reagent residuals from the evaporators (V1-V3) are passed over condensors (H4, H6, H9) to on or more distillation columns.

The process for producing a biodiesel of the present invention also can produce a co-product. In some embodiments, the co-product of the process of the present invention contains glycerin, fatty adds and an alcohol. Often the co-product further contains salts, soaps, water and other miscellaneous materials, which are often residuals from the reaction. In some embodiments, the co-product has a composition having from about 30% to about 40% glycerin, from about 50% to about 65% fatty acids, and from about 5% to about 10% alcohol and miscellaneous materials, expressed on a % v/v compositional basis. In some embodiments, the co-product has a composition having from about 34% to about 38% glycerin, from about 55% to about 60% fatty acids and from about 6% to about 7% alcohol and miscellaneous materials. In some embodiments, the co-product of the present invention can be used as a fuel source. In some embodiments, the co-product can be used as a fuel extender. As used herein, the phrase “fuel extender” refers to a substance that is an additive or supplement to a fuel, and can, for example, increase the volume of a particular fuel at a lower price, or can reduce particulate emissions resulting from use of the fuel. In some embodiments, the co-product of the present invention is used as a fuel source for operating the system of the present invention. In some embodiments, the co-product of the present invention is further processed. In some such embodiments, the further processing of the co-product of the present invention provides a food grade, a pharmaceutical grade, a livestock feed grade or a generally recognized as safe grade product. As used herein, the phrases “food grade,” “pharmaceutical grade” and “livestock grade” refers to a substance that meets its respective U.S. Food & Drug Administration standards and requirements to be used as food, a pharmaceutical and a livestock feed, respectively. As used herein, the phrase “generally recognized as safe” (GRAS) refers to any substance that meets the criteria of sections 201(s) and 409 of the U.S. Federal Food, Drug, and Cosmetic Act.

In some embodiments, the process for producing a biodiesel of the present invention includes:

-   1. producing the biodiesel in a system, the system having     -   a. optionally, at least one reagent storage vessel;     -   b. optionally, at least one reagent mixing vessel;     -   c. at least one batch reactor, where the batch reactor contains:         -   i. at least one agitator;         -   ii. at least one baffle, where optionally, the baffle is             heated;         -   iii. at least one pump; and         -   iv. at least one mixer; and     -   d. a post-reactor network, where the post-reactor network         contains:         -   i. optionally, at least one separator holding vessel;         -   ii. optionally, at least one separator;         -   iii. at least one polishing vessel;         -   iv. at least one co-product storage vessel;         -   v. optionally, at least one drying vessel; and         -   vi. at least one biodiesel storage vessel; -   2. selecting a feedstock; -   3. optionally, mixing at least a first reagent and a second reagent,     thereby, creating a reagent mixture; -   4. feeding the feedstock into a batch reactor; -   5. optionally, delivering a first reagent to the feedstock in the     batch reactor, thereby creating a first reaction mixture; -   6. optionally, delivering a second reagent to the feedstock in the     batch reactor, thereby creating a second reaction mixture; -   7. optionally, delivering the reagent mixture to the feedstock in     the batch reactor, thereby creating a reaction mixture; -   8. heating the reaction mixture of steps 5 and 6 or step 7, thereby     providing a heated reaction mixture; -   9. mixing the heated reaction mixture by:     -   a. agitating the reaction mixture using an agitator;     -   b. rotating the reaction mixture using at least one baffle; and     -   c. re-circulating the reaction mixture using a pump and a mixer,         -   for a predetermined time and under predetermined conditions             to produce a biodiesel-containing composition; -   10. separating the biodiesel of the biodiesel-containing composition     from a non-biodiesel composition, thereby obtaining a crude     biodiesel product; -   11. optionally, transferring the non-biodiesel composition to a     co-product storage tank, thereby retaining a co-product; -   12. polishing the crude biodiesel product, thereby obtaining a     polished biodiesel product; -   13. optionally, drying the polished biodiesel product, thereby     obtaining a biodiesel product; and -   14. storing the biodiesel product of either step 12 or step 13;     where if step 3 is performed, then step 7 is performed and steps 5     and 6 are not performed; and if step 3 is not performed, then step 7     is not performed and steps 5 and 6 are performed. In some such     embodiments, the system further makes a co-product. In some such     embodiments, the system is a batch system, and thus, the process is     a batch process. In some such embodiments, the system is a     batch-continuous flow system, and thus, the process is a     batch-continuous flow process.

In another aspect, the present invention provides a product produced from the system of the present invention. In some embodiments, the product made by the process of the present invention is a biodiesel. In some embodiments, the product is a biodiesel containing esters produced from a feedstock, such as, soy methyl esters produced from soybean oil.

In another aspect, the present invention provides a co-product produced from the system of the present invention. In some embodiments, the co-product made by the process of the present invention contains glycerin and fatty acids. In some embodiments, the co-product made by the system of the present invention is a fuel source. In some such embodiments, the co-product can fuel the system of the present invention.

In another aspect, the present invention provides a method of providing a biodiesel product to a user of the biodiesel product. In some such embodiments, the biodiesel product and the user of the biodiesel product are within the same geographic location. In some embodiments, the method of providing a biodiesel product to a user of the biodiesel product includes producing the biodiesel product by a system of the present invention. In some embodiments, the method of providing a biodiesel product includes producing the biodiesel product by a process of the present invention. In some embodiments, the geographic location of the biodiesel product and the end of the biodiesel product is a geographic radius from about 100 miles to about 1500 miles. In some such embodiments, the geographic region is from about 100 miles to about 750 miles. In some embodiments, the geographic location of the biodiesel product and the user of the biodiesel product is selected from a group consisting of a region, a state, a province, a county, a city, and a town. In such some embodiments, the region is selected from a group consisting of north, south, west, east, northeast, northwest, southeast southwest, midwest, and central, where the region is a part of a country, a state, a province, a county, a city or a town. For example, and without limitation, the region where the biodiesel is produced and the user of the biodiesel is located is in the northwest of the U.S. In some embodiments, the geographic location of the biodiesel product and the user of the biodiesel is at least one of the fifty states of the U.S. In some embodiments, the user is a supplier of biodiesel, an organization that uses biodiesel or an individual. Scheme 1 shows an embodiment of the method of providing a biodiesel product to an user of the biodiesel product of the present invention.

EXAMPLES

The following Examples are representative examples of the system of the present invention and the process of the present invention using the same. While the present invention has been described with specificity in accordance with certain embodiments of the present invention, the following Examples further serve only to exemplify and illustrate the present invention and are not intended to limit the same.

Example 1 Production of Methy Soy Esters Biodiesel

In a batch reactor, 6,500 gallons of soybean oil was added, which was heated to about 135° F. Separately, in a reagent mixing vessel (e.g., a tank), 500 lbs. of caustic soda (sodium hydroxide) was added to 2200 gallons of methanol (99.9% pure), which were mixed together (approximately 60 minutes) using an explosion proof stainless steel pump and a motor. The caustic soda-methanol mixture then was injected into the soy oil in at a rate of about 200 gallons per minute (gpm) by the stainless steep pump and the motor, while an agitator of the batch reactor was spinning at about 144 revolutions per minute (rpm). Immediately, a re-circulating 600 gpm pump (Gould MTX 3600 series) and a mixer (Ross LPD static mixer) of the batch reactor was turned on. The agitator, pump and mixer of the batch reactor were allowed to continue to blend and mix the reaction mixture for about 90 minutes, at which time the reaction for producing soy methyl esters essentially was completed. Then, the reaction mixture was transferred, using the same 600 gpm pump, to a separator holding vessel from which the reaction mixture was fed to a pair of separators (Alfa Laval MAP 207 and/or MOPX 209). The separators forced (at about 25 gpm) the heavy phase (about 40% glycerin, about 50% fatty acids, and about 10% methanol) away from the light phase (about 90% methyl esters, about 7% methanol, and about 3% water and soaps). The light phase, which was a crude biodiesel of soy methyl esters, was transferred to a polishing vessel and showered with an acid-treated liquid (water) polishing agent (phosphoric acid (35%); 4 gallons per 3,000 gallons of water) to pH balance (e.g., pH of about 6.5 to about 7.0) the crude biodiesel soy methyl esters and to wash out residual glycerin, methanol, and soaps. About 3,000 gallons of acid-treated liquid (water) polishing agent, washed 17,000 gallons of crude biodiesel.

Example 2 Production of Soy Methyl Esters Biodiesel

Soybean oil (about 8,650 gallons) was added to a batch reactor having a capacity of 21,000 gallons. Separately, 500 lbs. of caustic soda (sodium hydroxide) is added to a reagent mixing vessel, followed by 2,200 gallons of methanol, which was mixed to form a reagent mixture. The reagent mixture is then added to the batch reactor containing the soybean oil, and immediately, a 600 gpm pump (Gould MTX 3600 series) with a 75 hp motor (General Electric) was turned on to keep the soybean oil, methanol and caustic soda mixed and to re-circulate a portion of this reaction mixture through a static mixer (Ross LPD). After about 90 minutes, with the reaction essentially completed, the Gould 600 gpm pump with 75 hp motor further mixed the reaction mixture while transferring it to a separator holding vessel. The reaction mixture was processed further into a soy methyl ester biodiesel product as described in Example 1.

Examples 3-5 that follow exemplify the processing parameters that can be used to produce a biodiesel with a system and a process of the present invention, as described herein and further exemplified by Examples 1 and 2. The processing parameters are based on oils that have a moisture content of less than about 1% water. The biodiesel produced can be based on a single oil (e.g., only canola oil or soybean oil) or on a mixture of oils (e.g., canola oil and soybean oil).

Example 3 Processing Parameters for Crude Canola Oil and Crude Soybean Oil for Production of a Biodiesel

Temperate Range Processing Time Methanol Caustic Soda Oil (° F.) (Mins.) (% v/v) (lbs.) (Gals.) ≈60 to ≈70 ≈475 to ≈500 ≈20 ≈475 ≈8650 ≈70 to ≈80 ≈375 to ≈400 ≈20 ≈475 ≈8650 ≈80 to ≈90 ≈275 to ≈300 ≈20 ≈475 ≈8650  ≈90 to ≈100 ≈225 to ≈250 ≈20 ≈475 ≈8650 ≈100 to ≈110 ≈175 to ≈200 ≈21 ≈500 ≈8650 ≈110 to ≈120 ≈120 to ≈130 ≈22 ≈500 ≈8650 ≈120 to ≈130 ≈100 to ≈110 ≈24 ≈500 ≈8650 ≈130 to ≈140 ≈80 to ≈90 ≈26 ≈525 ≈8650 ≈140 to ≈150 ≈60 to ≈70 ≈27 ≈525 ≈8650 ≈150 to ≈160 ≈45 to ≈50 ≈28 ≈525 ≈8650 ≈160 to ≈170 ≈35 to ≈40 ≈29 ≈525 ≈8650

Example 4 Processing Parameters for De-Gummed Canola Oil and De-Gummed Soybean Oil for Production of a Biodiesel

Temperate Range Processing Time Methanol Caustic Soda Oil (° F.) (Mins.) (% v/v) (lbs.) (Gals.) ≈60 to ≈70 ≈475 to ≈500 ≈20 ≈450 ≈8650 ≈70 to ≈80 ≈375 to ≈400 ≈20 ≈450 ≈8650 ≈80 to ≈90 ≈275 to ≈300 ≈20 ≈450 ≈8650  ≈90 to ≈100 ≈225 to ≈250 ≈20 ≈450 ≈8650 ≈100 to ≈110 ≈175 to ≈200 ≈21 ≈475 ≈8650 ≈110 to ≈120 ≈120 to ≈130 ≈22 ≈475 ≈8650 ≈120 to ≈130 ≈100 to ≈110 ≈24 ≈475 ≈8650 ≈130 to ≈140 ≈80 to ≈90 ≈26 ≈475 ≈8650 ≈140 to ≈150 ≈65 to ≈70 ≈27 ≈500 ≈8650 ≈150 to ≈160 ≈45 to ≈50 ≈28 ≈500 ≈8650 ≈160 to ≈170 ≈35 to ≈40 ≈29 ≈500 ≈8650

Example 5 Processing Parameters for Refined, Bleached Canola Oil and Refined, Bleached Soybean Oil for Production of a Biodiesel

Temperate Range Processing Time Methanol Caustic Soda Oil (° F.) (Mins.) (% v/v) (lbs.) (Gals.) ≈60 to ≈70 ≈440 to ≈450 ≈20 ≈300 ≈8650 ≈70 to ≈80 ≈350 to ≈375 ≈20 ≈300 ≈8650 ≈80 to ≈90 ≈250 to ≈275 ≈20 ≈300 ≈8650  ≈90 to ≈100 ≈200 to ≈225 ≈20 ≈300 ≈8650 ≈100 to ≈110 ≈150 to ≈175 ≈21 ≈325 ≈8650 ≈110 to ≈120 ≈110 to ≈120 ≈22 ≈325 ≈8650 ≈120 to ≈130  ≈90 to ≈100 ≈24 ≈325 ≈8650 ≈130 to ≈140 ≈70 to ≈80 ≈25 ≈325 ≈8650 ≈140 to ≈150 ≈55 to ≈65 ≈26 ≈350 ≈8650 ≈150 to ≈160 ≈45 to ≈50 ≈27 ≈350 ≈8650 ≈160 to ≈170 ≈30 to ≈35 ≈28 ≈350 ≈8650

Example 6 Processing Parameters for Oils Containing Moisture

When a feedstock is an oil with a moisture content from about 1% to about 3%, the processing temperature most be slightly reduced and the processing time increased. For example, based on the tables of Examples 3-5, the processing temperature would be adjusted to a lower temperature that is one step below what would have been the processing temperature if the oil had a moisture content of less than about 1% water. To illustrate, e.g., processing refined, bleached soybean oil with a moisture content of less than about 1% would be at:

Temperate Range Processing Time Methanol Caustic Soda Oil (° F.) (Mins.) (% v/v) (lbs.) (Gals.) ≈110 to ≈120 ≈110 to ≈120 ≈22 ≈325 ≈8650

but, processing refined, bleached soybean oil with a moisture content of about 1% to about 3% water would be at:

Temperate Range Processing Time Methanol Caustic Soda Oil (° F.) (Mins.) (% v/v) (lbs.) (Gals.) ≈10 to ≈110 ≈150 to 175 ≈21 ≈325 ≈8650

For an oil with a moisture content greater than about 3% water, the oil would need to be dried before beginning the reaction with reagents to produce a biodiesel.

Example 7 Method of Providing a Biodiesel Product of the Present Invention to a User of the Biodiesel Product

A retail user (e.g. Pilot Travel Centers, LLC (Knoxville, Tenn.)) can transport a load (e.g., 7000 gallons) of a biodiesel product (B100) from a facility having a system of the present invention. (See e.g., VI of Scheme I). The retail user transports the load to a user facility (e.g. a Pilot Travel Center) where the biodiesel product is stored in a heated, B100 storage tank. The management of the user facility then blends the biodiesel into the diesel they are selling to create a biodiesel blend. For example, the management might blend a B2 biodiesel blend (i.e., 2% biodiesel, 98% diesel), which can be sold for most retail use; and blend a B20 biodiesel blend for a specialty market, which can be delivered via specialty designated and/or designed pumps (e.g., “BioPumps”). Also, the management can resell some B100 to any users wanting neat biodiesel.

The user facility (e.g., a Pilot Travel Center) could have several underground tanks that feed different filling islands (i.e., designated areas with means for delivering a fuel) at the facility. For example, the facility can have 6 pumps selling various grades of gasoline for cars and small trucks, which often require a tank containing a premium gasoline and a tank for regular gasoline; or the facility can have 16 pumps for truck filling, which are faster than the ones used to fill cars, some of which can pump premium diesel while other pumps deliver regular diesel. Often a biodiesel replaces the premium diesel at a facility.

The facility often has two or three underground tanks that are used to feed the 16 pumps on the filling islands. Thus, if the management of the facility wants to blend a B20 biodiesel and feed it to several pumps, this can be accomplished by using one of the underground tanks. The management fills 20% of the capacity of tanker truck with neat biodiesel (B100) from a facility that has a system of the present invention and produces the neat biodiesel, often by a process of the present invention. The management of the facility then drives the tanker containing the biodiesel to a diesel refinery and fills the remaining capacity of the tanker (80%) diesel. The tanker then returns to the facility and transfers the biodiesel blend into an underground tank. This type of blending a biodiesel blend is referred to as splash blending.

Or, the management of the facility can make a biodiesel blend by blending the neat biodiesel (B100) into the diesel using two tanks and a pump, and then transferring the blended biodiesel into an underground tank.

Because cold weather effects biodiesel and biodiesel blends—biodiesel gels at about 30° F.—popular cold flow additives (e.g., cold flow additives currently being used in diesel) can be used to get keep the biodiesel or biodiesel blend in a state where it flows at a temperature from about minus 10° F. to about minus 15° F. Also, if the facility is in a geographic location that experiences low temperatures then lower biodiesel blends can be used.

It is intended that each of the patents, patent applications, technical articles and reports, government, trade and industry publications, printed publications, including books and any of the aforementioned publications, mentioned in this patent document be hereby incorporated by reference in its entirety.

As those skilled in the art will appreciate, numerous changes and modifications can be made to the embodiments of the invention without departing from the spirit of the invention. It is intended that all such variations fall within the scope of the invention 

1) A system for producing a biodiesel from at least one batch load of feedstock, the system having at least one batch reactor, the batch reactor comprising at least one agitator substantially disposed inside the batch reactor, at least one baffle disposed inside the batch reactor, and at least one pump and at least one mixer disposed outside the batch reactor. 2) The system of claim 1, further comprising a post-reactor network, the post-reactor network comprising at least one co-product storage vessel and at least one biodiesel storage vessel, wherein the batch reactor is in fluid communication with the post-reactor network. 3) The system of claim 1 further comprising at least one reagent storage vessel, which is in fluid communication with the batch reactor. 4) The system of claim 1 further comprising at least one reagent mixing vessel, which is in fluid communication with the batch reactor. 5) The system of claim 2, wherein the post-reactor network further comprises at least one separator holding vessel, wherein the separator holding vessel is in fluid communication with the batch reactor, the at least one co-product storage vessel or a combination thereof. 6) The system as in claim 2, wherein the post-reactor network further comprises at least one separator, wherein the at least one separator is in fluid communication with the batch reactor, the at least one separator holding vessel, the at least one co-product storage vessel or a combination thereof. 7) The system of claim 6, wherein the at least one separator is a liquid phase separator or a centrifuge. 8) The system of claim 2, wherein the post-reactor network further comprises at least one polishing vessel, wherein the at least one polishing vessel is in fluid communication with the batch reactor, the at least one separator holding vessel, the at least one separator, the at least one co-product storage vessel, the at least one biodiesel storage vessel, or combination thereof. 9) The system of claim 8, wherein the at least one polishing vessel comprises a plurality of wash heads. 10) The system of claim 9, wherein the plurality of wash heads comprises from about 1 to about 20 wash heads. 11) The system of claim 9, wherein the plurality of wash heads is disposed in the roof of the polishing vessel, on an internal wall of the polishing vessel, on a pole inside the polishing vessel, on a rod inside the polishing vessel or a combination thereof. 12) The system of claim 2, wherein the post-reactor network further comprises at least one drying vessel, wherein the at least one drying vessel is in fluid communication with the at least one polishing vessel, the at least one biodiesel storage vessel, at least one reagent storage vessel or combination thereof. 13) The system of claim 12, wherein the at least one drying vessel comprises a heating element and a vacuum. 14) The system of claim 1, wherein the system further produces a co-product. 15) The system of claim 1, wherein the at least one baffle comprises a material selected from the group consisting of steel, carbon steel, stainless steel, chromium plated steel, copper, aluminum, metal alloy, thermally conductive polymer, polyvinyl chloride, expoxy, fluroroplastic, polypropylene, polyimide, polyacetal, polycarbonate, acrylonitrile-butadiene-styrene, polyetheretherketone, polybutylene, polyphenylene oxide, polyphenylene sulfide, liquid crystal polymer, and a combination thereof. 16) The system of claim 1, wherein the at least one baffle is affixed at an angle of about 90 degrees to an interior wall of the batch reactor. 17) The system of claim 1, wherein the at least one baffle is heated. 18) The system of claim 17, wherein the temperature of the heated baffle is from about 50° F. to about 200° F. 19) The system of claim 17, wherein the baffle comprises piping that is in fluid communication with a heat source. 20) The system of claim 19, wherein the piping is disposed substantially vertical to the height of the batch reactor. 21) The system of claim 19, wherein the heat source is steam. 22) The system of claim 1, wherein the batch reactor comprises from about 2 baffles to about 10 baffles. 23) The system of claim 1, wherein the at least one baffle comprises a cavity that allows the baffle to be substantially offset from an interior side of the batch reactor. 24) The system of claim 23, wherein the cavity is formed from two arms of the baffle disposed perpendicular to a main body of the baffle. 25) The system of claim 24, wherein the baffle further comprises a second cavity, which is disposed in the main body of the baffle. 26) The system of claim 23, wherein the cavity is formed from a concave nature of the baffle. 27) The system of claim 1, wherein the pump and the miser reintroduce a portion of reaction mixture into a remaining portion of reaction mixture, thereby providing a substantially homogeneous reaction mixture. 28) A process for producing a biodiesel from a feedstock using a batch reactor system having at least one baffle, the process involving the steps of: a) feeding the feedstock into the batch reactor system; b) delivering at least one reagent to the feedstock in the batch reactor system to create a reaction mixture; c) heating the reaction mixture; d) mixing the reaction mixture; and e) rotating the reaction mixture using the at least one baffle, wherein steps a) to e) are performed for a predetermined time and under predetermined, conditions to produce a biodiesel-containing composition; and f) separating the biodiesel of the biodiesel-containing composition from a non-biodiesel composition, thereby obtaining a crude biodiesel product; and g) polishing the crude biodiesel product, thereby obtaining a polished biodiesel product. 29) The process of claim 28, further comprising the steps of: a) mixing the at least one reagent with a second reagent, thereby creating a reagent mixture; and b) delivering the reagent mixture to the feedstock in the batch reactor, thereby, creating the reaction mixture. 30) The process of claim 28, further comprising the step of delivering a second reagent to the feedstock in the batch reactor. 31) The process of claim 28, further comprising the step of transferring the non-biodiesel composition to a co-product storage tank. 32) The process of claim 31, wherein the co-product comprises glycerin, fatty acids and alcohol. 33) The process of claim 32, wherein on a compositional basis the glycerin is from about 30% to about 40% v/v of the co-product, the fatty acids are from about 50% to about 60% v/v of the co-product and the alcohol is from about 5% to about 10% v/v of the co-product. 34) The process of claim 32, wherein on a compositional basis the glycerin is from about 34% to about 38% v/v of the co-product, the fatty acids are from about 55% to about 60% v/v of the co-product and the alcohol is from about 6% to about 7% v/v of the co-product. 35) The process of claim 32, wherein the co-product comprises a fuel source. 36) The process of claim 35, wherein the co-product fuel source fuels the batch reactor system. 37) The process of claim 31, wherein the co-product comprises a fuel extender. 38) The process of claim 31, further comprising the step of processing the co-product to provide a food grade product, pharmaceutical grad product, a livestock feed grade product or a generally recognized as safe product. 39) The process of claim 37, further comprising the step of drying the polished biodiesel product to obtain the biodiesel product. 40) The process of claim 39, wherein the drying step comprises heating the polished biodiesel under vacuum. 41) The process of claim 40, further comprising the steps of condensing vaporized residual reagent and polishing agent, and transferring condensed residual reagent and polishing agent to a reagent storage vessel. 42) The process of claim 28, wherein the feedstock comprises an organic oil. 43) The process of claim 28, wherein the feed stock comprises an animal fat. 44) The process of claim 28, wherein the feedstock comprises a plant source. 45) The process of claim 28, wherein the process further produces a co-product. 46) The process of claim 28, wherein the at least one reagent is an alcohol. 47) The process of claim 28, wherein the at least one reagent is a catalyst. 48) The process of claim 28, wherein the polishing step comprises a polishing agent. 49) The process of claim 28, wherein the predetermined time and the predetermined conditions for processing the feedstock; are selected from the group consisting of: Caustic Temperate Range Processing Time Methanol Soda Oil (° F.) (Mins.) (% v/v) (lbs.) (Gals.) about 60 to about 70 about 475 to about 500 about 20 about 475 about 8650; about 70 to about 80 about 375 to about 400 about 20 about 475 about 8650; about 80 to about 90 about 275 to about 300 about 20 about 475 about 8650; about 90 to about 100 about 225 to about 250 about 20 about 475 about 8650; about 100 to about 110 about 175 to about 200 about 21 about 500 about 8650; about 110 to about 120 about 120 to about 130 about 22 about 500 about 8650; about 120 to about 130 about 100 to about 110 about 24 about 500 about 8650; about 130 to about 140 about 80 to about 90 about 26 about 525 about 8650; about 140 to about 150 about 60 to about 70 about 27 about 525 about 8650; about 150 to about 160 about 45 to about 50 about 28 about 525 about 8650; and about 160 to about 170 about 35 to about 40 about 29 about 525 about
 8650.

50) The process of claim 28, wherein the predetermined time and the predetermined conditions for processing the feedstock are selected from the group consisting of: Caustic Temperate Range Processing Time Methanol Soda Oil (° F.) (Mins.) (% v/v) (lbs.) (Gals.) about 60 to about 70 about 475 to about 500 about 20 about 450 about 8650; about 70 to about 80 about 375 to about 400 about 20 about 450 about 8650; about 80 to about 90 about 275 to about 300 about 20 about 450 about 8650; about 90 to about 100 about 225 to about 250 about 20 about 450 about 8650; about 100 to about 110 about 175 to about 200 about 21 about 475 about 8650; about 110 to about 120 about 120 to about 130 about 22 about 475 about 8650; about 120 to about 130 about 100 to about 110 about 24 about 475 about 8650; about 130 to about 140 about 80 to about 90 about 26 about 475 about 8650; about 140 to about 150 about 65 to about 70 about 27 about 500 about 8650; about 150 to about 160 about 45 to about 50 about 28 about 500 about 8650; and about 160 to about 170 about 35 to about 40 about 29 about 500 about
 8650.

51) The process of claim 28, wherein the predetermined time and the predetermined conditions for processing the feedstock are selected from the group consisting of: Caustic Temperate Range Processing Time Methanol Soda Oil (° F.) (Mins.) (% v/v) (lbs.) (Gals.) about 60 to about 70 about 440 to about 450 about 20 about 300 about 8650; about 70 to about 80 about 350 to about 375 about 20 about 300 about 8650; about 80 to about 90 about 250 to about 275 about 20 about 300 about 8650; about 90 to about 100 about 200 to about 225 about 20 about 300 about 8650; about 100 to about 110 about 150 to about 175 about 21 about 325 about 8650; about 110 to about 120 about 110 to about 120 about 22 about 325 about 8650; about 120 to about 130 about 90 to about 100 about 24 about 325 about 8650; about 130 to about 140 about 70 to about 80 about 25 about 325 about 8650; about 140 to about 50 about 55 to about 65 about 26 about 350 about 8650; about 150 to about 160 about 45 to about 50 about 27 about 350 about 8650; and about 160 to about 170 about 30 to about 35 about 28 about 350 about
 8650. 